Carl Fredrik Carlborg

Beyond PDMS: off-stoichiometry thiol–ene (OSTE) based soft lithography for rapid prototyping of microfluidic devices

In this article we introduce a novel polymer platform based on off-stoichiometry thiol-enes (OSTEs), aiming to bridge the gap between research prototyping and commercial production of microfluidic devices. The polymers are based on the versatile UV-curable thiol-ene chemistry but takes advantage of off-stoichiometry ratios to enable important features for a prototyping system, such as one-step surface modifications, tuneable mechanical properties and leakage free sealing through direct UV-bonding. The platform exhibits many similarities with PDMS, such as rapid prototyping and uncomplicated processing but can at the same time mirror the mechanical and chemical properties of both PDMS as well as commercial grade thermoplastics. The OSTE-prepolymer can be cast using standard SU-8 on silicon masters and a table-top UV-lamp, the surface modifications are precisely grafted using a stencil mask and the bonding requires only a single UV-exposure. To illustrate the potential of the material we demonstrate key concepts important in microfluidic chip fabrication such as patterned surface modifications for hydrophobic stops, pneumatic valves using UV-lamination of stiff and rubbery materials as well as micromachining of chip-to-world connectors in the OSTE-materials.

On-chip temperature compensation in an integrated slot-waveguide ring resonator refractive index sensor array

We present an experimental study of an integrated slot-waveguide refractive index sensor array fabricated in silicon nitride on silica. We study the temperature dependence of the slot-waveguide ring resonator sensors and find that they show a low temperature dependence of -16.6 pm/K, while at the same time a large refractive index sensitivity of 240 nm per refractive index unit. Furthermore, by using on-chip temperature referencing, a differential temperature sensitivity of only 0.3 pm/K is obtained, without individual sensor calibration. This low value indicates good sensor-to-sensor repeatability, thus enabling use in highly parallel chemical assays. We demonstrate refractive index measurements during temperature drift and show a detection limit of 8.8 x 10-6 refractive index units in a 7 K temperature operating window, without external temperature control. Finally, we suggest the possibility of athermal slot-waveguide sensor design.

Sustained Superhydrophobic Friction Reduction at High Liquid Pressures and Large Flows

This Article introduces and experimentally explores a novel self-regulating method for reducing the friction losses in large microchannels at high liquid pressures and large liquid flows, overcoming previous limitations with regard to sustainable liquid pressure on a superhydrophobic surface. Our design of the superhydrophobic channel automatically adjusts the gas pressure in the lubricating air layer to the local liquid pressure in the channel. This is achieved by pneumatically connecting the liquid in the microchannel to the gas-pockets trapped at the channel wall through a pressure feedback channel. When liquid enters the feedback channel, it compresses the air and increases the pressure in the gas-pocket. This reduces the pressure drop over the gas-liquid interface and increases the maximum sustainable liquid pressure. We define a dimensionless figure of merit for superhydropbic flows, W(F) = P(L)D/γ cos(θ(c)), which expresses the fluidic energy carrying capacity of a superhydrophobic microchannel. We experimentally verify that our geometry can sustain three times higher liquid pressure before collapsing, and we measured better friction-reducing properties at higher W(F) values than in previous works. The design is ultimately limited in time by the gas-exchange over the gas-liquid interface at pressures exceeding the Laplace pressure. This method could be applicable for reducing near-wall laminar friction in both micro and macro scale flows.

A High-Yield Process for 3-D Large-Scale Integrated Microfluidic Networks in PDMS

This paper presents an uncomplicated high-yield fabrication process for creating large-scale integrated (LSI) 3-D microfluidic networks in poly(dimethylsiloxane) (PDMS). The key innovation lays in the robust definition of miniaturized out-of-plane fluidic interconnecting channels (=vias) between stacked layers of microfluidic channels in standard PDMS. Unblocked vias are essential for creating 3-D microfluidic networks. Previous methods either suffered from limited yield in achieving unblocked vias due to residual membranes obstructing the vias after polymerization, or required complicated and/or manual procedures to remove the blocking membranes. In contrast, our method prevents the formation of residual membranes by inhibiting the PDMS polymerization on top of the mold features that define the vias. In addition to providing unblocked vias, the inhibition process also leaves a partially cured, sticky flat-top surface that adheres well to other surfaces and that allows self-sealing stacking of several PDMS layers. We demonstrate the new method by manufacturing a densely perforated PDMS membrane and an LSI 3-D PDMS microfluidic channel network. We also characterize the inhibition mechanism and study the critical process parameters. We demonstrate that the method is suitable for structuring PDMS layers with a thickness down to 10 m.

Reaction injection molding and direct covalent bonding of OSTE+ polymer microfluidic devices

In this article, we present OSTE+RIM, a novel reaction injection molding (RIM) process that combines the merits of off-stoichiometric thiol–ene epoxy (OSTE+) thermosetting polymers with the fabrica ...

Fabrication and transfer of fragile 3D PDMS microstructures

We present a method for PDMS microfabrication of fragile membranes and 3D fluidic networks, using a surface modified water-dissolvable release material, poly(vinyl alcohol), as a tool for handling, ...

One step integration of gold coated sensors with OSTE polymer cartridges by low temperature dry bonding

We propose and demonstrate a novel one step method to integrate gold coated sensors with cartridges by dry covalent bonding. The cartridges are replica molded in an UV-curable off-stoichiometry thiol-ene (OSTE) polymer, featuring an excess of thiol functional groups that covalently bond to the surface of gold coated sensors upon contact. The method is demonstrated by the integration of a gold coated quartz crystal to a microfludic OSTE cartridge. The resulting bond interface is shown to be completely homogenous and void free and the package is tested successfully to a differential pressure of up to 2 bars. The performance of the biosensor chip is evaluated by measuring the unspecific binding of 0.5% albumin, resulting in a total frequency drop 205 Hz. This approach delivers a simple but rapid high quality integration aiming for the production of robust, low cost and disposable biosensor chips.

OSTE - a novel polymer system developed for Lab-on-Chip

OSTE polymer has the aim to address today’s dissemination gap between successful lab-on-chip research and the healthcare setting. We have formulated and demonstrated a novel, superior, polymer system, OSTE, and its manufacturing platform, which is based on the mixture of three monomers: thiols, -enes and epoxies. The uniqueness of the OSTE approach stems from the curing in two distinct steps: after the first cure, an intermediate polymer is formed which is ideally suited for surface modifications and bonding; after the second cure we obtain an inert and robust polymer. Our vision is that OSTE has the potential to form a de-facto standard for research and development of high performance labs-on-chip in academia and industry.

Microchannels with Substantial Friction Reduction at Large Pressure and Large Flow

This paper introduces and experimentally verifies a self-regulating method for reducing the friction losses in large microchannels at high liquid pressures and large liquid flows, overcoming limitations with regard to sustainable liquid pressure on a superhydrophobic surface. Our design of the superhydrophobic channel creates an automatic adjustment of the gas pressure in the lubricating air layer to the local liquid pressure in the channel. This is achieved by pneumatically connecting the liquid in the microchannel to the air pockets trapped at channel wall trough a pressure feedback channel. When liquid enters the feedback channel it compresses the air and increases the pressure in the air pocket. This reduces the pressure drop over the air-liquid interface and increases the maximum sustainable liquid pressure. We define a dimensionless fluidic number, WF = PLDh/¿cos¿c, which expresses the fluidic energy carrying capacity of a superhydrophobic microchannel. We experimentally verified that our geometry can sustain several times higher liquid pressure before collapsing, and we measured better friction reducing properties at higher WF values than in previous works. This method could be applicable for reducing near-wall laminar friction in both micro- and macroscale flows.

Off-stoichiometry improves the photostructuring of thiol–enes through diffusion-induced monomer depletion

Thiol–enes are a group of alternating copolymers with highly ordered networks and are used in a wide range of applications. Here, “click” chemistry photostructuring in off-stoichiometric thiol–enes is shown to induce microscale polymeric compositional gradients due to species diffusion between non-illuminated and illuminated regions, creating two narrow zones with distinct compositions on either side of the photomask feature boundary: a densely cross-linked zone in the illuminated region and a zone with an unpolymerized highly off-stoichiometric monomer composition in the non-illuminated region. Using confocal Raman microscopy, it is here explained how species diffusion causes such intricate compositional gradients in the polymer and how off-stoichiometry results in improved image transfer accuracy in thiol–ene photostructuring. Furthermore, increasing the functional group off-stoichiometry and decreasing the photomask feature size is shown to amplify the induced gradients, which potentially leads to a new methodology for microstructuring.